OverWatch - Installation - Genie Smartlink (OLD Pre 2021 Harness) - Installation Instructions

OverWatch - Installation - Genie Smartlink (OLD Pre 2021 Harness) - Installation Instructions

Notes
This Tech Doc was written to help customers with very old Genie Smartlink installations
Alert
The latest version of the Genie Smartlink kit utilises a daughter board with spring loaded contacts that connect to the Genie control board. As we no longer publish or maintain an installation manual for this version kit, it is being published as a Tech Doc here for those customers that still have this old kit version in service.
Warning
Please note that the Software Version 9 update is not compatible with the Pre 2021 harness in this old kit. You will need to update your harness in order to update your software.

Operator Sensor
Installation Steps:
1. Drill two 5.0mm holes to mount the operator sensor (in the position shown in the diagram below).
The sensor should be mounted at an angle of 40 degrees.
2. Drill a 4.0mm hole for the P-Clip installation. 


3. Mount the module in the located position using the supplied M4 washers, nuts and bolts.




4. Remove the bottom cover off the joystick enclosure to expose the internals


5. Install the supplied cable gland (in the location shown in the image below)
6. Feed the wire from the operator sensor into the enclosure.
Care should be taken to make sure that the cable gland does not obstruct or damage the control box serial number printing.


7. Drill the hole for the P-Clip in the location shown in the image.




Control Module 
Installation Steps:
1. From the machine connections loom, cut and crimp the following wires (in the table below). 

The connection instructions will be explained in more detail in the next few steps

To install the system power +24V:
2. Connect the Red wire from the machine connections loom into Pin 1 of the E-STOP.


To install the system ground 0V:
3. Splice and solder the Black wire from the machine connection loom to the Brown wire from the connector C3


To install the Deadman connection 1:
4. The connection is on the White wire (coming out of the joystick).
5. Locate the White wire and cut it in half
6. Solder the Green wire from the machine connection loom to the White wire (on the side that is coming from the joystick).


To install the Deadman connection 2:
7. Solder the Blue wire from the machine connection loom on the other side of the White wire (that was cut). 


To install the Joystick Signal input:
8. Splice and solder the Grey wire onto the Yellow wire coming from the joystick (JOYSTICK AXIS – PIN1)


9. Remove the buzzer to have better access to the main circuit board.

 
10. Carefully remove the protective coating on the circuit board to expose the through hole push button switch pads

The protective coating can be removed by using a small pick on the: Drive Select Button, Elevate Select Button, Horn Button

11. Solder the Purple wire from the machine connection loom to the pin behind the Drive Select button


12. Solder the Orange wire from the machine connection loom to the pin behind the Elevate Select button


13. Solder the Blue and Green wires from RLY1 on the machine connection loom, to horn switch pins


14. Once the connections have been soldered to the PCB, use a small amount of hot glue to cover and seal the connections


15. Using the supplied P-clip, secure the wire connections using the PCB mounting hole and screw
16. Place a cable tie on the circuit board side of the P-Clip to negate force on the wires.


17. Place the supplied relay in the position, next to the circuit board


18. Mount the control module in the location shown in the image below.


19. Route the cable from the operator sensor through the installed cable gland, using the path shown in the image below.


20. Connect the 8-Pin connector from the Operator Sensor and the 12-Pin connector from the machine connection loom to the Overwatch ECU.



Post Installation Configuration
Overview
After the Overwatch has been installed it must be configured with the parameters to suit the machine. Follow the instructions below to configure the Overwatch.

Minimum system requirements
Any smart phone, tablet or laptop that meets the following requirements:
  1. The device can connect to a Wi-Fi access point supporting 802.11 b/g/n (2.4GHz) protocol
  2. The device has an up to date Firefox or Safari web browser installed (2019 onwards). 
Wi-Fi Connection & Web Page
Access To enable the Wi-Fi connection on the Overwatch to complete the configuration follow the steps below.
1. Power down the platform control box with the ESTOP
2. Wait 10 seconds
3. Power up the platform control box with the ESTOP
4. While standing in the operator position, switch on the Overwatch
5. As the welcome chime starts to play, cover the sensor. The LED will flash white then black to acknowledge.
6. Remove your hand from the sensor. The LED will flash white then black to acknowledge.
7. After covering then uncovering the sensor this way 2 more times, "Wi-Fi On" will be announced
8. On your Wi-Fi enabled device (laptop, tablet, smartphone, etc), show the available wireless networks
9. Select the wireless network (starts with “overwatch”) to connect to the Overwatch
10. When prompted, enter the password “12345678”
11. Open your web browser (Safari or Firefox)
12. Enter the following into the address bar http://192.168.4.1 to open the Overwatch main page


Machine Model Selection
Follow the instructions below to configure the Overwatch.
1. Select the Setup option
2. If there is a password field at the bottom of the page, follow the instructions in Change Model Configuration to obtain the password and enter the password field
3. Select the EWP Model from the drop-down list and click Set
4. Click on Proceed to Test to begin the installation test
 


Installation Test
After the model configuration has been set or updated, an Installation Test must be performed. This will ensure the installation has been correctly performed and the Overwatch is functioning correctly. Follow the instructions on the web page to complete the Installation Test.


Change Model Configuration
To reconfigure the Overwatch for a different model requires an authorisation password. The authorisation password is generated from the EQSS website.

Go to the Reconfiguration page and follow the instructions to create an authorisation password.

Settings
The OEM Settings page defines preset OEM parameters
See the sections below for details on each parameter:


Polarity and Input Style
The table below describes each setting 

Bypass

Date and Time

Connection Schematics